2008 BMW 335d E91

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Jakg

Original Poster:

3,463 posts

168 months

Tuesday 7th June 2022
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Family holiday to Bath, nearly 1,000 miles over the week - sunroof proving very handy!



Calipers need a clean, though...



When doing the front calipers I noticed the rear pads were low, so a new set goes on



The air filter is a Pipercross cleanable one - I cleaned it (done this several times on other cars before) before I went away, but a couple of weeks later got an emissions warning on the dash.

INPA said it was the DPF, which was suspicious as the holiday had been perfect for the DPF to regen.

There was also a fault for the MAF sensor - from some advice online I swapped the air filter back to an old standard one and the MAF reading at idle literally halved.
Some poking of the Pipercross filter and it looks like it's not filtering very well anymore.



The foam has come away from the metal frame - so swapped back to a standard one.

Unfortunately, the MAF fault was still present, and I was worried if I didn't fix it soon I might have bigger problems from the DPF, so fitted a new Bosch MAF



The MAF + filter seems to have fixed everything, but I'm a bit frustrated - the air filter is like £40 new but sold as cleanable but after a single clean disintegrated, and the MAF was £90...

I *suspect* the oil (i.e. dirt retention additive) killed the MAF, and the filter disintegrated during the cleaning process.
I don't think I did anything wrong and have done it before without issues, but maybe I did, who knows.

Certainly made me rethink fancy filters though.

Also due some other service items, so an oil service and a new pollen filter:



This idea is totally original and not at all stolen from another E91 335d on here... an E92 rear brace.
The E91 has a brace that runs from just in front of the rear wheels to the diff carrier.
The E92 has a brace that runs from the centre of the body, to brackets attached to the front of the rear subframe.



You can have both fitted together, and it wasn't very expensive so I picked one up.

I'm not going to pretend it makes a difference, but I had some rear suspension work to do (more later) and planned on doing a couple of jobs while it was in the air, but then things got in the way and I'm taking it piecemeal.

Jakg said:
The car has a grey headlining, but the sunroof was from a beige headlining car so the sunroofs headlining is beige - I'll never have it closed so not essential but I'd like to swap them
The headlining can be swapped while fitted to the car which is why I didn't do this while fitting it.

I practiced on the old sunroof but it's a two person job when done on the car.

The glass comes out (the panels are only held in with a couple of screws)



The headlining panels are held in with screws accessed from above, and you can contort the headlining out.



Bye bye beige



Putting it all back together was a little tricky though, as the glass needed re-aligning, but was obviously much further out of alignment having been removed from the car completely.

Finally, estatey things:

Somehow it's possible to *just* fit a 2.5m long, 600mm wide bit of wood in the car and still close all the doors... but not if you have any passengers.
I don't recommend it.



Edited by Jakg on Tuesday 7th June 22:55


Edited by Jakg on Sunday 19th June 21:42

helix402

7,861 posts

182 months

Wednesday 8th June 2022
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Happy to see another 335d getting some tlc. Nice brace!

Jakg

Original Poster:

3,463 posts

168 months

Sunday 19th June 2022
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Replaced the rear arms (specifically the "tension struts" or "guide rods" which is the not very descriptive BMW name) with M3 versions.

Replaces one of the bushes for a ball joint - more info here - https://www.1addicts.com/forums/showthread.php?t=1...



I bought one TRW and one Lemforder as the price difference was crazy, but both "manufacturers" (both are owned by ZF) castings' are identical and even have the BMW part number ground off...

When I replaced the suspension, the first drive I took I was listening out for funny noises and heard some funny noises from the rear end, kind of like a ticking.
I thought it was maybe a backplate catching under cornering but a quick prod didn't seem to do much.
That was a while ago, but with the windows down a lot on holiday the noise really started to get on my nerves.
It could also be described as a squeaking at low speeds, and Googling that brought up a lot more results.

It looks to be a common fault attributed to one of the lower ball joints on the rear wheel hub.
The most common "fix" is to pierce the rubber boot on the ball joint and spray lubricant in which makes the noise go away - this seems absolutely mental to me as water will quickly replace all the oil which will leak out, and then it'll just corrode and get worse.

New ball joints were only about £13 each so I thought I'd try swapping them at the same time.



Unfortunately, I just didn't have the tools to take it out - or at least I had plenty of tools (hydraulic puller, drifts etc) but none seemed to work for this application, despite doing basically the same job on my Z4 & MG ZT.

I ended up shelling out £85 on big threaded bush removal kit with 20-odd incrementally sized cups.
I'd tried making one before and found it useless so had expectations, and thought I'd just have to use the cups with my puller and chuck the threaded rod, but it actually went really well.
I'm not sure if the rods were thicker (several supplied, I used the largest that'd fit - M14), or the ball joints weren't rusted in as much as before, but I got them out using no more force than a spanner to counterhold and a 1/2" ratchet (although it certainly gave my arm a workout).







With the ball joints exposed, both had a little play, which I'm sure was what was causing the noise.



Both the arms and ball joints took me quite a while on one side, and then about 20 mins on the other side once I knew what I was doing.

All back together and I felt the difference basically straight away - the car feels more solid, tighter, even at low speeds.
I think the worn ball joints probably had more of an impact than just noise.

Edited by Jakg on Thursday 1st September 22:46

Jakg

Original Poster:

3,463 posts

168 months

Wednesday 17th August 2022
quotequote all
So, the sunroof stopped working again.

It was doing the "almost-closing-but-bouncing-back" thing. Some investigation showed the wind deflector wasn't properly retracting.

A closer look



And the wind deflector arm has snapped just before the hinge.

Luckily the deflector comes out without any disassembly



Then I found something wierd



Three spare screws, one wedged under the hinge - perfect position that the force of the glass closing snapped the arm around it.

They are the screws that attach the headliner to the sunroof at the front... and i'm not missing any!

I think that when it was removed from the donor car, they put the screws on the frame and forgot about it.
I stored the sunroof on it's side for a year or so and the screws must've got into the sunroof drain.

Fitted to the car, driven a couple of thousand miles over rough roads and they've come back out again and got wedged.

Really not lucky with sunroofs!

Luckily the sunroof works fine with the deflector removed. A new one is £100, so maybe I can glue it back together, or maybe I'll get a new one.

Also got it a friend



E70 3.0sd - same engine as my 335d. And it has a panoramic sunroof too. Which works. For now...

Jakg

Original Poster:

3,463 posts

168 months

Saturday 8th October 2022
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Slow puncture became less slow, but the inside edge of the tyre was damaged as well so new rubber time.



And a non-oily update - I even polished it. A detailer I am not...


Court_S

12,937 posts

177 months

Sunday 9th October 2022
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Looks well. I think the touring is my favourite E9x car.

I think Sparkling Graphite is a great colour.

Jakg

Original Poster:

3,463 posts

168 months

Tuesday 8th November 2022
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Copied the idea from my X5 and replaced the power steering fluid. Flushed about 800ml through - left is original, right is the last flush. It's hard to see but it's cleaned up a lot, but clearly not completely!



Replaced the climate control panel because the retaining clips on mine were busted and it wasn't sitting flush





My wife took the car out and reported a myriad of warning lights - ABS, tyre pressure, transmission fault etc.

I suspected something electrical, but nothing obvious when scanned and alternator was charging fine.

Next day I thought I'd check the voltage again just before I left...



Looks like the alternator was dead.

I found TIS / YouTube quite unhelpful for this job - there's loads of videos about doing it on M57-engined cars, but there's so many configurations that it's not quite the same for each model. My favourite was watching a video of a 320d where there's loads of room up front... because 2 cylinders are missing!

I removed:
Engine cover,
Airbox,
Undertray,
Rad fan (remove the power steering radiator - that one wasn't mentioned anywhere),
Aux belt (not fully, just off the bits on that side of the engine to avoid removing the stretch AC belt),
Disconnect intercooler -> inlet manifold hose,
Disconnect battery,
Move radiator top hose to the side to get to the connections on the back of the alternator.



With all that I could dismount the alternator. I carefully got it rotated out of it's home, but it was stuck in front of the engine - it's too large to fit between the rad fan and crossmember to come out the bottom, and out the top is fouled by the EGR cooler / coolant hoses. The videos I watched showed it coming out the bottom - but that was an E60.

I was only going to swap the regulator anyway so it being stuck in the car was only a little annoying.



The brittle plastic cover on the back did not want to come off in a single piece.

With the old regulator removed it was clear that the brushes were the problem - one was noticeably shorter than the other and presumably not making contact with the slip ring any more.



Back together, fingers crossed and...



Ideally I'd of replaced the belts at the same time, but this was a bit of a rush job. The aux belt is is in perfect condition, and the AC belt doesn't look that worn so I'm not too worried.

One of the few times I've been let down by being unable to use the car due to an actual fault (vs me breaking something being hamfisted). Luckily only about £30 and several hours to get it fixed.

Edited by Jakg on Tuesday 8th November 00:25

d_a_n1979

8,387 posts

72 months

Tuesday 8th November 2022
quotequote all
Jakg said:
Copied the idea from my X5 and replaced the power steering fluid. Flushed about 800ml through - left is original, right is the last flush. It's hard to see but it's cleaned up a lot, but clearly not completely!



Replaced the climate control panel because the retaining clips on mine were busted and it wasn't sitting flush





My wife took the car out and reported a myriad of warning lights - ABS, tyre pressure, transmission fault etc.

I suspected something electrical, but nothing obvious when scanned and alternator was charging fine.

Next day I thought I'd check the voltage again just before I left...



Looks like the alternator was dead.

I found TIS / YouTube quite unhelpful for this job - there's loads of videos about doing it on M57-engined cars, but there's so many configurations that it's not quite the same for each model. My favourite was watching a video of a 320d where there's loads of room up front... because 2 cylinders are missing!

I removed:
Engine cover,
Airbox,
Undertray,
Rad fan (remove the power steering radiator - that one wasn't mentioned anywhere),
Aux belt (not fully, just off the bits on that side of the engine to avoid removing the stretch AC belt),
Disconnect intercooler -> inlet manifold hose,
Disconnect battery,
Move radiator top hose to the side to get to the connections on the back of the alternator.



With all that I could dismount the alternator. I carefully got it rotated out of it's home, but it was stuck in front of the engine - it's too large to fit between the rad fan and crossmember to come out the bottom, and out the top is fouled by the EGR cooler / coolant hoses. The videos I watched showed it coming out the bottom - but that was an E60.

I was only going to swap the regulator anyway so it being stuck in the car was only a little annoying.



The brittle plastic cover on the back did not want to come off in a single piece.

With the old regulator removed it was clear that the brushes were the problem - one was noticeably shorter than the other and presumably not making contact with the slip ring any more.



Back together, fingers crossed and...



Ideally I'd of replaced the belts at the same time, but this was a bit of a rush job. The aux belt is is in perfect condition, and the AC belt doesn't look that worn so I'm not too worried.

One of the few times I've been let down by being unable to use the car due to an actual fault (vs me breaking something being hamfisted). Luckily only about £30 and several hours to get it fixed.

Edited by Jakg on Tuesday 8th November 00:25
Good job well done there pal biggrin

More patience (and probably smaller hands) than me! I'd have absolutely broken something laugh

Jakg

Original Poster:

3,463 posts

168 months

Friday 23rd December 2022
quotequote all
Had a couple of close-calls parking in the garage - if you get it close to the wall it's long enough you can open the boot with the garage door closed.

I already had a mirror on the side but put an old baby car mirror in front angled down so you can see the gap from the drivers seat. I'm aware of the tennis ball & string method, but this works for any car.



Swapped the ashtray & cigarette lighter for the sunglasses oddments tray - more space, but now my coins rattle around so not totally sold.





Got fed up of getting filthy every time I went in the boot so a quick wash in the rain




helix402

7,861 posts

182 months

Saturday 24th December 2022
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Looking good. I did the same sunglasses holder swop on mine.

Jakg

Original Poster:

3,463 posts

168 months

Thursday 16th February 2023
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Booked in for new tyres tomorrow so luckily/unlucky had a blowout today.

No spare and non-runflats meant a trip home on the RAC multifit wheel of shame.

Luckily the garage could fit me in a day earlier so all fixed now - Goodyear Eagle F1 6's all round.




Jakg

Original Poster:

3,463 posts

168 months

Saturday 25th February 2023
quotequote all
Jakg said:
Although the car doesn't have stop start, it has "Brake Energy Regeneration" (i.e. selective charging), which means it needs an AGM battery.
Normally I'd get a Bosch S5 / Varta one, but it was £180.
I found a Yuasa for £140, but it turns out that the Halfords battery has identical specs, is also made by Yuasa, has a longer warranty and was £148 so I went for that.
Been getting a million warnings on the dashboard, thought it was a bit suspicious. Battery was charging fine, but was only 12.1v, even after charging it up fully. Swapped to the old battery and all good.

Luckily I got a Halfords one, as the next day I walked out with a new one under warranty.



Also updated the maps - this was mid battery issue so in the absence of a proper 12v power supply, used a trickle charger and the spare battery in parallel.






Jakg

Original Poster:

3,463 posts

168 months

Monday 5th June 2023
quotequote all
Jakg said:
Jakg said:
Although the car doesn't have stop start, it has "Brake Energy Regeneration" (i.e. selective charging), which means it needs an AGM battery.
Normally I'd get a Bosch S5 / Varta one, but it was £180.
I found a Yuasa for £140, but it turns out that the Halfords battery has identical specs, is also made by Yuasa, has a longer warranty and was £148 so I went for that.
Been getting a million warnings on the dashboard, thought it was a bit suspicious. Battery was charging fine, but was only 12.1v, even after charging it up fully. Swapped to the old battery and all good.

Luckily I got a Halfords one, as the next day I walked out with a new one under warranty.
Unfortunately this came back.



I was suggested to disconnect the battery, touch the battery leads together for a bit and then retry.

I thought this sounded nonsense, but it's not come back since...





The 572hp, 12 cylinder, 6WD fleet


Jakg

Original Poster:

3,463 posts

168 months

Monday 31st July 2023
quotequote all


Assumed front sidelights were faulty, so spent (wasted) a long time checking them all before taking a look at the back.

One of the passenger right tail lights had stopped working (yeah, the message said left...)



Pulled the bulbs out



Two of the bulbs had smashed - but how?

E91 pre-LCI lights melt a bit with the heat from the bulbs, but mine had melted so far the mount had come loose and smashed all the bulbs



Luckily a replacement was less than £15.

Jakg

Original Poster:

3,463 posts

168 months

Wednesday 9th August 2023
quotequote all
My car has the sport steering wheel, with paddles.



I wanted to upgrade to the m-sport wheel, but because of the paddles they are quite rare/expensive (>£100).

Luckily I found a bare wheel on eBay, with paddle cut outs but no paddles / trim etc for £45.



The paddles and airbag are a straight swap with my wheel, but the trim is £100 and second hand they aren't much cheaper but all quite worn.

It was cheaper to buy another m-sport non-paddle wheel for £25, just for the trim



As you can see, the coating is peeling off and quite worn, so I had to refurb it.

Acetone got most of the rubberised coating off.



Primed and then painted matt black

I painted the switch surrounds as well so they'd match



Old wheel off



Then swapped over the paddles and rebuilt the steering wheel controls with my old buttons but the new painted surrounds

My wheel has a diamond/star button, which are programmable using the CCC iDrive.

Unfortunately with the CIC system that's been retrofitted, you can't reprogram them - so I used the swapped to the buttons from the other wheel that had change audio source / air recirculate buttons instead as thats what they actually do.



The trim came out ok, but there was some damage I hadn't realised to the trim itself



Built up



new v old



All back together



In the picture it looks a poor colour match, but I think it's the lighting - under natural light its not noticable.



Edited by Jakg on Monday 5th February 07:59

pmorg4

720 posts

116 months

Wednesday 9th August 2023
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That last picture looks spot on. Those rubberised trims used in various places around the car are a nuisance, they just don't last. I had to refinish my steering wheel trim too, especially after I had the leather retrimmed by Royal Steering Wheels which really showed up how bad the trim was. I'm not totally happy with the finish on mine either, but it's far better than it looked before. Ideally I want it to look OE but just without the horrid rubberised coating.

Welcome to the world of CIC with the two useless buttons. I'm not really sure why I need a recirculation button on my steering wheel when I have a dedicated recirculation button a few centimetres away, especially given that the one on the steering wheel doesn't seem able to switch back to the automatic recirculation mode which I use most of the time. I guess BMW realised they had two spare button slots and had to fill them with something. The old CCC system was better, although still somewhat limited in the actions you could assign to it.

Jakg

Original Poster:

3,463 posts

168 months

Tuesday 10th October 2023
quotequote all
Jakg said:
So, the sunroof stopped working again.

It was doing the "almost-closing-but-bouncing-back" thing. Some investigation showed the wind deflector wasn't properly retracting.

A closer look



And the wind deflector arm has snapped just before the hinge.
Had no luck trying to get a new wind deflector - I finally found someone with a broken sunroof who'd sell it separately, but then it fell through.

A quick search on Facebook later and I ended up being offered a complete sunroof for £50... go on then.

Last time it was tricky fitting it in the car because of the sheer size:
Jakg said:
So I took the X5 instead - fitted easily with room to spare



Deflector removed and offered up



The deflector is spring loaded to pop up, and the plastic tabs go under angled clips that move backwards/forwards to allow it to raise and force it back down. The springs are quite strong to work against airflow while driving.

Unfortunately, I got the spring the wrong way round and as I was fitting it the tab snapped off the side!

I took some time to come back with a more positive attitude - I now have two broken wind deflectors.



Some cutting later to create a repair panel



Some glue (Q bond) later - not pretty, but as good as a repair as can be done with the space available.



Fitment round two and... it broke again.

The hinge section - which i hadn't touched - broke a bit, but was still usable.

But the repair didn't hold once the tension in the spring built up.

I think with age the deflectors get brittle and break easily (i.e. with a little mishandling).

I'm frustrated but at least I didn't break a brand new one at £170...

Jakg said:
Really not lucky with sunroofs!
You can say that again!

Court_S

12,937 posts

177 months

Wednesday 11th October 2023
quotequote all
What a ball ache.

What’s the plan now to fix it?

Jakg

Original Poster:

3,463 posts

168 months

Wednesday 11th October 2023
quotequote all
Court_S said:
What’s the plan now to fix it?
The plan is to leave it well alone! It works fine, just a bit more buffety without the deflector.

pmorg4

720 posts

116 months

Wednesday 11th October 2023
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I think if I had a pan roof I'd be tempted to just leave it permanently closed and enjoy the extra light it brings. It's about the only meaningful option that my 335i doesn't have, and I sway between wishing I had one and being glad that I don't have one biggrin